Modular belting for use in the food processing industry

ABSTRACT

Modular belting for use in the food processing industry having a smooth, planed surface, and an apparatus and method for refurbishing damaged belting. The apparatus includes a frame with a conveyor system. A mechanism is attached to the frame for removing a desired amount of the belting surface as the belting moves relative to the frame on the conveyor system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a Continuation application of prior application Ser. No.08/818,424, filed on Mar. 17, 1997, now U.S. Pat. No. 5,882,157, whichis a Divisional application of prior application Ser. No. 08/306,099,filed on Sep. 14, 1994, which has matured into U.S. Pat. No. 5,691,737.

FIELD OF THE INVENTION

The present invention relates to an apparatus for refurbishingindustrial belting. In particular, the present invention relates modularbelting for use in the food industry and to an apparatus whichrefurbishes expensive modular conveyor belting for reuse in the foodindustry.

BACKGROUND OF THE INVENTION

In industry, conveyor systems are used for transporting products betweenvarious industrial process stations. In particular, food industryconveyor systems use belting for transporting food product during foodprocessing.

In the food processing industry, raw food product is transported onconveyor systems using modular belting. The modular belting is formedfrom universally shaped injection-molded plastic modules which havegenerally smooth and impervious surfaces. The belting modules areflexibly connected together to form desired lengths and widths ofconveyor belting.

The cost of modular belting is very expensive, and increases with beltsize. Modular belting is used in the food processing industry because itmeets U.S. Department of Agriculture (USDA) and other regulatorysanitary and cleanliness requirements. Food processes are inspected on adaily basis by USDA representatives to insure the processes are meetingfederal regulations.

After a period of use, the modular belting surface-is no longer smoothand impervious. Modular belting becomes damaged from knife scribes andreturn carriers in the form of cuts and scraps in the belt surfaces. Thedamaged modular belt surfaces no longer meet USDA inspectionrequirements and federal regulations since the damaged surfaces may besusceptible to the build-up of bacteria and other organisms. In thepast, the only alternative was to discard the damaged belting andreplace it at a very expensive cost.

SUMMARY OF THE INVENTION

The present invention is an apparatus and method for refurbishingconveyor belting. Particularly, the present invention relates to anapparatus and method for refurbishing expensive modular conveyor beltingfor reuse in the food industry.

In one embodiment, the present invention includes an apparatus forrefurbishing belting which has a damaged portion. The apparatus includesa frame and a conveyor system. A mechanism is attached to the frame forremoving a desired amount of the belting as the belting moves relativeto the frame on the conveyor system.

The mechanism for removing a desired amount of the belting surface mayinclude a selectively rotatable, generally cylindrically shaped memberhaving at least one blade extending from a longitudinal surface thereof.The mechanism for removing a desired amount of the belting may also beaccomplished by other mechanical, electrical or chemical means, such asthe use of a drum sander.

Additionally, the mechanism for removing a desired amount of the beltingsurface may include a mechanism for applying uniform pressure to thebelting surface. The mechanism for applying pressure to the beltingsurface may include a pair of pressure hold down devices located on eachside of the apparatus frame. Additionally, the apparatus may include amechanism for discharging belting removed.

The belt refurbishing apparatus may also include a mechanism foradjusting the vertical position of the belting surface relative to themechanism for removing a desired amount of the belting surface.

In a preferred embodiment, the present invention includes a system forrefurbishing modular belting used on conveyor systems in the foodprocessing industry, the modular belting having a damaged surface. Therefurbishing system includes a frame with a conveyor bed passing throughthe frame. A mechanism is attached to the conveyor bed for selectivelymoving the damaged modular belting on the conveyor bed relative to theframe. A mechanism is also attached to the frame for removing a desiredamount of the damaged surface of the modular belting as the beltingmoves through the frame.

Additionally, a control mechanism is included for controlling the amountof surface removed, by adjusting the position of the conveyor bedrelative to the mechanism for removing the belting surface.

In one embodiment, the removal mechanism includes a mechanism forplaning the modular belting surface having at least one rotating blade.Alternatively, the removal mechanism may include a drum sander.

Additionally, the system may include a mechanism for buffing theconveyor belting after the damaged surface has been removed; a mechanismfor selectively imparting a drag force on the modular belting to aid inremoving the belting surface; a mechanism for adjusting the conveyorframe to a accommodate different widths and lengths of the conveyorbelting; and a mechanism for applying uniform pressure to the modularbelting surface.

In yet another embodiment, the present invention may include a controlmechanism for varying the speed of movement of the conveyor bed relativeto the frame, and a control mechanism for varying the speed of planingthe belting surface.

The present invention refurbishes modular conveyor belting for reuse,which in the past was discarded and replaced at an expensive cost. Themodular belting may be refurbished a number of times, depending upon theamount of belting removed.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be further described with reference to accompanyingdrawings where like numbers refer to like parts in several views andwherein:

FIG. 1 is a diagrammatic view of a belt refurbishing apparatus inaccordance with the present invention;

FIG. 2A is a plan view of a portion of damaged modular belting shown inFIG. 1;

FIG. 2B is an end view of the portion of damaged modular belting shownin FIG. 2A;

FIG. 2C is an end view of the damaged modular belting of FIGS. 2A and 2Bshown in an alternate position;

FIG. 3 is a partial view showing planing of a modular belting surface inaccordance with the belt refurbishing apparatus of the presentinvention;

FIG. 4A is a plan view of a portion of refurbished modular belting;

FIG. 4B is an end view of the portion of refurbished modular beltingshown in 4A; and

FIG. 5 is a control diagram which includes a graphic representation ofinput signals and output signals in accordance with one embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates generally to an apparatus for refurbishingindustrial belting used in conveyor systems.

Particularly, modular belting used on conveyor systems in the foodprocessing industry becomes damaged after a period of use. In the past,when the damaged belting no longer met federal regulations for use, thebelting was discarded and replaced at an expensive cost. The presentinvention refurbishes damaged modular belting to its previous smooth andimpervious form, which meets federal regulations for reuse in the foodindustry, at a fraction of the replacement cost.

FIG. 1 shows a belt refurbishing system in accordance with the presentinvention generally at 10. The belt refurbishing system 10 generallyincludes a surface removal system 12 and a conveyor system 14. Ingeneral, the conveyor system 14 carries damaged belting which is to berefurbished through the surface removal system 12 for removing thedamaged belting surface.

The belting to be refurbished is shown generally at 16 on conveyorsystem 14. In one preferred embodiment, the belting 16 is modularbelting which is generally used in the food processing industry. Aportion of the modular belting 16 is shown in FIGS. 2A, 2B and 2C. Asshown in FIG. 2A, belting 16 includes modules 18 which are rotatablyconnected together. Modules 18 are formed from injection molded plasticmaterial, such as acetal, polyurethane, polyethylene, acetalpolyethylene blends, or similar materials. The modules 18, such as thosecommonly manufactured by Rexnord, Intralox, Falcon, Cambridge, etc. areuniversally formed to fit most food industry conveying systems.

The modules 18 include a top surface 20 and hinge extensions 22. Themodules are flexibly connected together by passing a pin (not shown)through corresponding hinge extensions 22 and securing the pin in placewith a fastener 23. As shown in FIG. 2C, belting formed of modules 18 isflexible at hinge extensions 22.

Belting 16 may be provided in various widths and lengths. Belting widthsrange up to any useable width. Accordingly, to achieve wider beltwidths, manufacturers commonly combine a combination of modules 18.

Top surface 20 is a molded surface which is generally flat. In the foodprocessing industry, as the modular belting 16 carries raw food throughvarious process stations, the modular belting 16 top surface 20 becomesdamaged from knife scribes and return carriers in the form of cuts andscrapes on the top surface shown generally at 24.

The damaged top surface 24 may be susceptible to the build-up ofbacteria and other organisms. Food processes undergo daily inspectionsfor meeting federal sanitary requirements. When the belting 16 isdamaged to the point that it no longer meets federal regulations, in thepast, the only alternative was to discard the damaged belt and replaceit at a very expensive cost.

The present belt refurbishing invention 10 removes the damaged portion24 of the top surface 20. Top surface 20 is once again smooth, andsuitable for use on food industry conveying systems.

Referring to FIG. 1, surface removal system 12 is securely attached toframe 11. Surface removal system 12 removes the damaged portion 24 oftop surface 20, restoring belting 16 in condition for reuse.

In a preferred embodiment shown in FIG. 1, surface removal system 12includes a belt planing system 30. Planing system 30 includes a planingdrum 32 having blades 34, pressure devices 36, damaged belting dischargechute 40, motor 42, and controller 44.

Planing drum 32 is rotatably connected within frame 11. Planing drum 32is generally cylindrically shaped with blades 34 extending from planingdrum 32 along its longitudinal surface. Blades 34 are secured withinplaning drum 32, with the amount of blades 34 extending from planingdrum 32 being adjustable. In a preferred embodiment as shown in FIG. 1,four blades 34 are equally spaced along the cylindrical surface ofplaning drum 32.

Planing drum 32 is mechanically coupled (43) to motor 42 for rotating ata desired speed as indicated by directional arrow 46. The rotation ofplaning drum 32 is controlled by controller 44. Controller 44 controlsthe starting and stopping of planing drum 32. Additionally, motor 42 mayinclude a variable frequency drive coupled to planing drum 32, whichallows controller 44 to also control the speed of rotation of planingdrum 32.

In operation, as the damaged belting 16 moves past planing drum 32,indicated by directional arrow 48, a pair of pressure devices 36 applyuniform pressure to the top surface of belting 16. Pressure devices 36include pressure hold down bars 50 and pressure plates 52. Pressureplates 52 have a width which is greater or equal to the width of belting16. In operation, pressure plates 52 are in contact with the top surfaceof belting 16. Pressure hold down bars 50 are located above pressureplates 52 and secured to frame 11. Pressure hold down bars 50 adjust theamount of uniform pressure applied to belting 16.

Pressure devices 36 keep belting 16 from buckling as belting 16 passesthrough planing system 30. Pressure devices 36 are located on each sideof planing drum 32, and are spaced a distance apart which is generallyless then the width of a module 18. As shown at 54, as blades 34 rotate,they extend between pressure devices 36 for cutting the top surface 20of belting 16.

Additionally, guards 38 are located around planing-drum 32. Guards 38provide safety protection from blades 34 and also a conduit for blades34 to throw removed belting material into the damaged belting dischargearea 40.

In one embodiment, the damaged belting discharge 40 is connected to avacuum for collecting the damaged belting material at a centrallocation. The collected damaged belting bi-product is in a form suitablefor recycling. The belting bi-product may be melted down and used againfor injection molded processes.

The present invention provides advantages over past wasteful industrypractices. In the past, when damaged belting no longer met inspectionrequirements, it was discarded and was in a form too large for easyrecycling. With the advantages of the present invention, the belting isrefurbished for reuse, and the damaged belting bi-product is recyclablefor use in other injection molded products.

Conveyor system 14 moves belting 16 through frame 11 for removal of thedamaged top surface 24 by surface removal system 24. Conveyor system 14includes conveyor bed 60, conveyor bed surface 62, pull through drivesprocket 64, motor 66, control 68, brake spool 70, conveyor bed lengthadjustment 72, and surface removal adjustment 74.

Conveyor bed 60 extends through frame 11 and is securely attached andsupported by frame 11. Alternatively, conveyor bed 60 may extend throughframe 11, or be located next to frame 11, and be supported by theprocess floor.

Conveyor bed 60 has a conveyor bed surface 62. Conveyor bed surface 62is formed of a material which will not damage the belting 16 passingover the conveyor bed surface 62, and which has a low coefficient offriction between the conveyor bed surface 62 and belting 16. In oneembodiment, conveyor bed surface 62 is formed of plastic or a materialsimilar to the belting 16.

Conveyor bed 60 is secured to frame 11, indicated at 76. Drive sprocket64 is located at one end of conveyor bed 60 and brake spool 70 islocated at an opposite end of conveyor end 60. Belting 16 is loaded ontoconveyor bed 60 and around drive sprocket 64 and brake spool 70 as shownin FIG. 1.

Drive sprocket 64 pulls the belting 16 through surface removal system 12over the conveyor bed 60. If necessary, drive sprocket 64 may be easilychanged out to accommodate a specific manufacturer's type of belting,since conveyor drive sprockets for each type of belting all have acommon universal bolt system. Drive sprocket 64 is mechanically coupled(67) to motor 66 which drives drive sprocket 64. Controller 68 allowsfor control of drive sprocket 64, such as start and stop operations. Inone embodiment, motor 66 includes a variable frequency drive coupled todrive sprocket 64 for varying the speed of conveyor belting 16. With thevariable frequency drive, an operator is able to adjust the speed of theconveyor system 14 at controller 68.

Brake spool 70 is rotatably attached to the conveyor bed 60 at theopposite end of the drive sprocket 64. Brake spool 70 follows drivesprocket 64 for guiding belting 16 across conveyor bed 60. Additionally,brake spool 70 imparts an adjustable drag force on belting 16 to keepthe belting 16 tight to the conveyor bed surface 62, and to keep belting16 from buckling as it moves through surface removal system 12.

The amount of damaged top surface which needs to be removed varies frombelting to belting, depending upon how deep the cuts and scrapes areinto the belting 16. The present invention provides for precisionadjustment of the amount of top surface to be removed by surface removalsystem 12. In a preferred embodiment, the planing drum 32 remainsstationary within the surface removal system 12 and the amount of topsurface to be removed is adjusted by conveyor bed surface removaladjustment 74. Surface removal adjustment 74 provides for precisionadjustment of conveyor bed 60 in a vertical direction. Additionally,surface removal adjustment 74 provides a leveling adjustment of conveyorbed 60. Alternatively, it is recognized that conveyor bed 60 couldremain stationary and the amount of top surface removed would beadjusted by adjusting removal system 12 planing system 30.

Additionally, the length of conveyor bed 60 may be adjusted by conveyorbed length adjustment 72. The conveyor bed length adjustment 72 adjustsconveyor bed 60 to accommodate different sized belting or to take upexcess belting after the belting 16 is loaded onto the conveyor bed 60.

FIG. 3 shows a close-up partial view of the belt refurbishing 10 planingsystem 30 in operation (pressure devices 36 and guards 38 not shown). Asshown, planing system 30 planes away the undesirable damaged top surface24 of belting 16, resulting in the smooth top surface 20 as shown inFIGS. 4A and 4B. The resulting top surface is smooth and impervious,free of any knife cuts or scraps. Additionally, the belt refurbishingsystem 10 of the present invention provides a truer cut surface than theoriginally molded belting 16, which was generally flat.

The present invention allows plastic modular belting to be refurbished anumber of times. Since the surface removal adjustment 74 allows fineadjustment of the amount of surface to be removed, where the surfacecuts are not very deep, only a small portion of the surface, as isnecessary, is removed. Since the top surface 20 of the belting modulesare relatively thick, belting 16 may be refurbished a number of timesinto a condition acceptable for reuse in process conveyor systems.

Referring to FIG. 1, an additional buffer system, shown at 80, may alsobe used for providing a smooth buffed finish to the refurbished belting16. The buffer system 80 includes a flap wheel buffer 82, a motor 84, acontroller 86, and a support system 88.

Flap wheel buffer 82 is supported by support system 88. Flap wheelbuffer 82 may be selectively adjusted to come in contact with belting 16after it has passed through surface removal system 12. Flap wheel buffer82 is mechanically coupled to motor 84 and is controlled by controller86. Motor 84 rotates flap wheel buffer 82 for buffing and shining thetop surface 20 of belting 16. It is recognized that buffer system 80does not have to remain in continuous contact with belting 16, butrather be controlled to contact belting 16 when desired.

It may be necessary that the belting be sanitized or disinfected priorto refurbishing or after refurbishing. In one embodiment, a belt washeris used to clean the modular belting. The belt washer may include aseries of nozzles or spray jets for pressure cleaning of the belting.Additionally, a chemical sanitizer, such as a chloride based solution,may be used for sanitizing and disinfecting the belting.

It is also recognized that the present invention, shown in FIG. 1 set upto refurbish a continuous loop of belting 16, could be used as acontinuous feed belt refurbishing system. In this operation, a rubberdrum roller system 90 may be located above drive sprocket 64 to retainbelting 16 against drive sprocket 64.

Additionally, it is recognized that the belt refurbishing system 10 isoperable as a portable unit, and could be located at the end of anexisting conveyor system to be refurbished. In such an operation, theconveyor belting would simply be fed from the existing conveyor systemonto the belt refurbishing system for surface removal and returned tothe conveyor system.

It is also recognized that the damaged surface to be removed could beremoved in one pass through the surface removal system 12, oraccomplished through multiple passes through the surface removal system12. Additionally, planing system 30 may include one blade or a number ofblades, or may include additional planing drums for multiple cutting oftop surface 20. In one embodiment, the speed of the cutters is variableand also the speed at which the conveyor system moves the beltingthrough the surface removal system 12.

Additionally, as shown in FIG. 5, the belt refurbishing system 10 may beincorporated into a process having a centralized control system as showngenerally at 100. In one embodiment, the centralized control system 100includes a controller 102. The controller 102 includes a mechanismcapable of forming logical operations, such as a sequence of logicgates, switches, a computer or other microprocessor based processcontrol unit. Controller 102 provides for manual or automatic operationof belt refurbishing system 10. Controller 102 accepts user inputs 104,such as desired cutting speed, conveyor speed, cutting depth, belttension, belt drive tension, and buffer system enable. Additionally,controller 102 accepts system alarms 106, other sensors 108, and otherinputs 109. In response, the controller 102 automatically controls thebelt refurbishing system 10 by providing timed outputs 110, 112, 114,116, and 120.

It is also recognized that other systems may be used for surface removalsystem 12 while still remaining within the scope of the presentinvention. For example, it is contemplated that the surface removalsystem 12 may include a drum sander for removing portions of damaged topsurface 24. Although the use of a drum sander is contemplated, a planingsystem is preferred due to the inherent problems associated with sandingplastic molded materials. It is recognized that with the use of a drumsander, the plastic belting is more susceptible to warping, a truesurface may not be achieved, and a fine adjustment of the portion to beremoved may not be accomplished.

Additionally, the belt refurbishing system of the present invention isable to remove damaged portions on the side of the modular belting byusing a side surface removal device such as a planer or circulatingblade mechanism similar to a table saw.

It is recognized that the present invention may be used to refurbishalmost any type of industrial belting formed of plastic, rubber, orsimilar materials. Additionally, the belt refurbishing process may beused as a preliminary step to resurface damaged belting by applying anadditional substrate over the refurbished belting.

The belt refurbishing system of the present invention provides aneconomical and efficient apparatus and method for removing the damagedtop surface of plastic modular belting commonly used on the conveyorsystems in the food processing industry. With the use of the presentinvention, costly plastic modular belting no longer need be discardedwhen damaged, but may be repeatedly refurbished for use while meetingfederal regulations.

It will be understood that this disclosure is, in many respects, onlyillustrative. Changes may be made in details, particularly in matters ofshape, size, material, and arrangement of parts, without exceeding thescope of the invention. Accordingly, the scope of the invention is asdefined in the language of the appended claims.

What is claimed is:
 1. A belting module suitable for use in a conveyingsystem in the food processing industry, the belting module having a foodcarrying surface, the belting module comprising:a molded body made of agenerally rigid polymeric material, the molded body including a firstmajor surface and a second major surface, wherein the first majorsurface is a smooth, planed surface, and wherein the first major surfaceis the food carrying surface; and a coupling mechanism extending fromthe molded body for rotatably coupling the belting module to a secondbelting module as part of a length of belting used in the conveyingsystem.
 2. The belting module of claim 1, wherein the first majorsurface is polished.
 3. The belting module of claim 1, further whereinthe first major surface is chemically sanitized.
 4. The belting moduleof claim 1, wherein the molded body further includes a side surface,wherein the side surface is a planed surface.
 5. The belting module ofclaim 1, wherein the coupling mechanism is formed as part of the moldedbody.